I-beam construction in a hockey blade core

ABSTRACT

A reinforced hockey stick blade and a related method of manufacture are provided. The hockey stick blade can include a core element defining one or more longitudinal channels bounded by an upper core portion, a lower core portion, and a bridge portion interconnecting the upper and lower core portions. The hockey stick blade can additionally include a plurality of fiber-reinforced plies substantially encapsulating the core element and a reinforcing material received within the one or more longitudinal channels. The reinforcing material can extend longitudinally from a first channel end portion to a second channel end portion, and can include woven or unidirectional fiber-reinforced plies. The reinforcing material can additionally extend transversely across the channel to form a blade structure having increased blade strength and durability over existing composite hockey stick blades.

BACKGROUND OF THE INVENTION

The present invention relates to a composite hockey stick blade and arelated method of manufacture.

There are a variety of commercially available hockey bladeconstructions. The internal configuration of these hockey blades may bealtered depending on the characteristics desired by a player, includingthe feel, curve, flex and strength. In some cases, the characteristicsdesired by a player depend on the position of the player. For example, adefensive player may desire a certain blade configuration, while anoffensive player may desire a different blade configuration. In someconfigurations, adjusting the blade characteristics may require acomplete redesign of numerous elements of the blade. This results inadded expense for stick manufacturers to provide different models ofblades with different characteristics.

Some modern hockey manufacturers have moved from more traditional woodblades to a blade made partially of foam. Foam constructions provide theblade with a low-weight construction. However, the foam constructionscan be less durable, weak and can provide insufficient strength forachieving high velocities when striking a puck. Current constructions tostrengthen the foam may add significant thickness to the blade, whichmay make the blade clumsy for the fine movements and puck handlingrequired of players. Further, some foam configurations include separatepieces of foam in the blade. These configurations can be undesirable dueto added processing, material handling, and assembly costs in creatingand working with the separate foam pieces.

SUMMARY OF THE INVENTION

A composite hockey stick blade and a related method of manufactureprovide a reinforced core element with increased blade strength anddurability.

In one embodiment, a composite hockey stick blade is provided. Thecomposite hockey stick blade includes a core element defining a channelbounded by an upper core portion, a lower core portion and one or morebridge portions. The hockey stick blade can additionally includemultiple fiber-reinforced plies substantially encapsulating the coreelement and a reinforcing material received within the channel. Thereinforcing material can extend longitudinally from a first channel endportion to a second channel end portion, and can extend transverselyacross the channel to interconnect fiber-reinforced plies on opposingsides of the core element.

In another embodiment, the core element defines an upper channel and alower channel. The upper and lower channels are spaced apart from eachother, with a core element therebetween, and extend from the heel of thehockey stick blade toward the toe of the hockey stick blade. The coreelement optionally is a unitary structural foam core.

In yet another embodiment, the reinforcing material includes a pluralityof fiber-reinforced plies. The fiber-reinforced plies can be co-curablewith the plies substantially encapsulating the core element, and caninclude graphite, aramid, and/or fiberglass fibers. The fibers can beunidirectional or woven, optionally being pre-impregnated with an epoxyresin prior to lay-up of the blade preform.

In still another embodiment, the reinforcing material within the channelcan be in the form of a tubular element. The tubular element can bedisposed substantially entirely within the channel. Optionally, theouter surfaces of the tubular element can generally lay within an outerplane within which the front and/or rear surfaces of the core elementare disposed.

In even another embodiment, a method for manufacturing a reinforcedhockey stick blade is provided. The method includes defining a channelin a foam core, inserting a reinforcing material in the channel, andlaying up one or more outer plies over the foam core to achieve a bladepreform. The reinforcing material can extend longitudinally from a firstchannel end portion to a second channel end portion, and can extendtransversely across the channel to interconnect one or more outer plieson opposing sides of the foam core. The blade preform can be curedwithin a mold cavity having the exterior shape of the finished blade toform a composite hockey stick blade having improved strength anddurability.

In a further embodiment, the above method includes forming a foam coreincluding an upper core portion, an intermediate core portion, a lowercore portion, and a bridge portion integral with the upper, intermediateand lower core portions. The foam core can define an upper channelbetween the upper and intermediate core portions, and a lower channelbetween the intermediate and lower core portions. The upper and lowerchannels can be substantially parallel to each other, being spaced apartby the intermediate core portion.

In yet a further embodiment, the above method includes inserting aplurality of fiber-reinforced strips within the upper and lowerchannels. The plurality of fiber-reinforced strips can be coextensive inlength with the respective channel, including a width at least as wideas the width of the foam core. The plurality of fiber-reinforced stripscan be pre-impregnated with an epoxy resin, and can include sections ofwoven or unidirectional fiber-reinforced tape.

The embodiments herein can maintain the light weight of a compositeblade, while providing reinforcement for the foam core. As a result, theblade can be manufactured with a greater maximum breaking force withoutadding significant thickness to the blade. Where desired, the compositeblade can be modified to achieve tailored performance characteristics,including modifications to the core element, the reinforcing material,the outer skin plies, and the addition of internal adhesive films.

These and other objects, advantages, and features of the invention willbe more fully understood and appreciated by reference to the descriptionof the current embodiments and the drawings.

Before embodiments of the invention are explained in detail, it is to beunderstood that the invention is not limited to the details of operationor to the details of construction and the arrangement of the componentsset forth in the following description or illustrated in the drawings.The invention may be implemented in various other embodiments and may bepracticed or carried out in alternative ways not expressly disclosedherein. Also, it is to be understood that the phraseology andterminology used herein are for the purpose of description and shouldnot be regarded as limiting. The use of “including” and “comprising” andvariations thereof is meant to encompass the items listed thereafter andequivalents thereof as well as additional items and equivalents thereof.Further, enumeration may be used in the description of variousembodiments. Unless otherwise expressly stated, the use of enumerationshould not be construed as limiting the invention to any specific orderor number of components. Nor should the use of enumeration be construedas excluding from the scope of the invention any additional steps orcomponents that might be combined with or into the enumerated steps orcomponents.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front view of a composite hockey stick blade in accordancewith an embodiment of the invention;

FIG. 2 is a sectional view taken along line 2-2 of FIG. 1;

FIG. 3 is a front view of a core element of the composite hockey stickblade of FIG. 1 illustrating upper and lower channels;

FIG. 4 is a front view of the core element of FIG. 3 includingreinforcing material received within the upper and lower channels;

FIG. 5 is a flow chart for a method for forming the composite hockeystick blade of FIGS. 1-4;

FIG. 6 includes graphs illustrating test data for a composite hockeystick blade formed according to the method of FIG. 5;

FIG. 7 is a front view of a composite hockey stick blade in accordancewith another embodiment of invention;

FIG. 8 is a front view of a core element of the composite hockey stickblade of FIG. 7;

FIG. 9 is a front view of a composite hockey stick blade in accordancewith another embodiment of invention;

FIG. 10 is a sectional view taken along line 10-10 of FIG. 9;

FIG. 11 is a front view of a composite hockey stick blade in accordancewith another embodiment of invention;

FIG. 12 is a sectional view taken along line 12-12 of FIG. 11;

FIG. 13 is a front view of a composite hockey stick blade in accordancewith another embodiment of the invention;

FIG. 14 is a sectional view taken along line 14-14 of FIG. 13;

FIG. 15 is a section view of a composite hockey stick blade inaccordance with another embodiment of the invention illustrating aremoved skin ply;

FIG. 16 is a section view of a composite hockey stick blade inaccordance with another embodiment of the invention illustrating anadditional channel;

FIG. 17 is a front view of a composite hockey stick blade in accordancewith another embodiment of the invention;

FIG. 18 is a sectional view taken along line 18-18 of FIG. 17;

FIG. 19 is a front view of a composite hockey stick blade in accordancewith another embodiment of the invention; and

FIG. 20 is a sectional view taken along line 20-20 of FIG. 19.

DESCRIPTION OF THE CURRENT EMBODIMENTS

I. Overview

The current embodiments relate to a composite hockey stick blade and amethod for forming the same. The composite hockey stick blade and methodprovide a reinforced core element with increased blade strength anddurability. Embodiments can be used in connection with ice hockeysticks, goalie sticks, hockey sticks adapted for non-slip surfaces, andhockey sticks whose size and dimensions vary from that of the hockeysticks described below.

A composite hockey stick blade in accordance with a current embodimentis shown in FIG. 1 and generally designated 10. The blade 10 includes aheel portion 12 and a toe portion 14 defining a length therebetween. Asused herein, the heel portion 12 can generally include the lowermostregion of the blade 10 adjacent a hosel 15, including at least a portionof the upwardly curved transition to the hosel 15. The blade 10additionally includes a top edge 16 and a bottom edge 18 for defining aheight, and a front face 17 opposite a back face 19 for defining awidth.

The blade 10 includes a core element 20 positioned within the interiorof the blade 10, generally extending from the heel portion 12 to the toeportion 14. The core element 20 can include a foam material selected tohave a desired density and rigidity. Suitable foam materials includeDivinycell® HP130 structural foam available from DIAB Group AB, orAIREX® C71 structural foam available from 3A Composite CoreTechnologies. Other foam or non-foam materials can be used in otherembodiments. Though shown as a unitary structure, the core element 20can include multiple adjoining or interlocking segments having the sameor different properties.

As noted above, the core element 20, referred to herein as a foam core20, is reinforced to provide added strength to the blade 10. Inparticular, the foam core 20 includes one or more longitudinal channels30, 32 for receipt of a fiber-reinforced material therein. Thefiber-reinforced material can include a prepreg, optionally the sameprepreg used in the lay-up for the hockey stick blade 10. As set forthin greater detail below, the one or more strips of the fiber-reinforcedmaterial can be inserted transversely through the channels 30, 32 toreinforce the foam core 20 without materially adding to the thickness ofthe blade 10.

The blade 10 shown in FIG. 1 includes the foam core 20 and channels 30,32 shown in phantom. It should be noted that the foam core 20 andchannels 30, 32 in FIG. 1 are depicted for illustrative purposes. Thefoam core 20 and channels 30, 32 would likely be concealed by the otherelements of the blade 10, if the other elements of the blade 10 areopaque. Illustrative configurations are also shown in connection withother embodiments shown in FIGS. 7, 9, 11, 13, 17 and 19.

II. Construction

A blade 10 including a reinforced foam core 20 in accordance with acurrent embodiment will now be described in more detail with referenceto FIGS. 2-4. The reinforced foam core 20 may include a first core face22, a second core face 24, a top core edge 26, a bottom core edge 28, atoe core edge 27 and a heel core edge 29. One or more channels 30, 32may be defined in the foam core 20 at a location between the top coreedge 26 and the bottom core edge 28, and between the toe core edge 27and the heel core edge 29.

Each channel may have a first channel end 36, 38 proximate the toeregion 14 and a second channel end, 40, 42 proximate the heel region 12.Optionally, more or less than the illustrated two channels may bedefined in foam core 20. The channels 30, 32 may extend from the firstcore face 22 to the second core face 24 to form a hole through the foamcore 20. The channels 30, 32 may be bounded by an upper core portion 50,a lower core portion 52 and a middle core portion 54. The channels 30,32 may be a variety of heights (taken between upper core portion 50 andmiddle core portion 54, and between middle core portion 54 and lowercore portion 52). For example, the channels 30, 32 may be between 0.02and 0.1 inches high, optionally between 0.04 and 0.08 inches high, andfurther optionally 0.0625 inches high. The channels 30, 32 may be in avariety of configurations, including substantially horizontal, angled,curved and substantially vertical. Further, the channels 30, 32 may bein a variety of configurations in relation to one another, includingsubstantially parallel and substantially non-parallel. The configurationof the channels may be selected based on the desired characteristics ofthe blade 10.

As also shown in FIG. 3, the upper core portion 50, the middle coreportion 54 and the lower core portion 52 may be attached to andcontinuous with one another via a first foam core bridge member 60,optionally in the toe region 14, and/or a second foam core bridge member62, optionally in the heel region. The bridge members 60, 62 and theremainder of the foam core 20 may form a unitary, one-piece, monolithicstructure, with the bridge members 60, 62 closing the first ends 36, 38and second ends 40, 42 of the channels 30, 32. It is also contemplatedthat only one bridge member 60, 62 may be used. In this configuration,the end of the channels 30, 32 without a bridge member 60, 62 may beleft open and may not be closed. Optionally, in this configuration, theend of the channels 30, 32 without a bridge member 60, 62 may be closedby other elements, including one or more skin ply layers 100, 102, 104,106, which will be further described below.

As noted above, the channels 30, 32 can receive a fiber-reinforcedmaterial therein. The fiber-reinforced material can include any materialadapted to strengthen the foam core 20. For example, thefiber-reinforced material can include woven or unidirectional graphitefiber prepreg, fiberglass fiber prepreg, aramid fiber prepreg, blendfiber prepreg, as well as any of the above plies not yet impregnatedwith a resin. Still other materials can be used in other embodimentswhere desired.

Referring now to FIG. 2, one or more strips of fiber-reinforced material70, 72, 74, 76 may be inserted transversely through the channels 30, 32so that a first strip end 78, 80, 82, 84 may project from the foam core20 adjacent the first core face 22, and so that a second strip end 86,88, 90, 92 may project from the foam core 20 adjacent the second coreface 24. The first strip ends 78, 80, 82, 84 and second strip ends 86,88, 90, 92 may be folded over, so they are positioned adjacent the firstcore face 22 and second core face 24. Additional strips may overlap andlayer on top of the strips 70, 72, 74, 76. Optionally, the same numberof layered strips may be positioned adjacent the first core face 22 andthe second core face 24 to form a relatively flat area for the at leastone skin ply layer 100, 102, 104, 106 to bond to, as further describedbelow. For example, the embodiment illustrated in FIG. 2 includes asingle layer of strips positioned adjacent the first core face 22 andthe second core face 24. If a second strip is added over the top of eachof the illustrated strips 70, 72, 74, 76, a “double” layer of stripswould be positioned adjacent the first core face 22 and the second coreface 24, forming a relatively flat area adjacent each of the first coreface 22 and second core face 24. Additional supplemental strips of fiberreinforced material 94, 96 may be inserted transversely through thechannels 30, 32 so that the additional strips 94, 96 may be positionedsubstantially completely within the channel 30, 32.

The reinforcing strips 70, 72, 74, 76 and the supplemental strips 94, 96may be made of any suitable material, including woven fabrics materialpreimpregnated with resin (prepreg material) and unidirectional tapematerial preimpregnated with resin. The fibers in the prepreg materialmay be any suitable fibers including carbon fibers, graphite fibers,aramid fibers and fiberglass fibers, for example. The total thickness ofthe reinforcing strips 70, 72, 74, 76 and the supplemental strips 94, 96may be any total thickness suitable for placement through the channels30, 32. For example, the total thickness of the strips and supplementalstrips may be between 0.005 and 0.4 inches, optionally between 0.007 and0.3 inches, and further optionally between 0.01 and 0.2 inches. Thetotal thickness may be altered depending on the desired characteristicsof the blade 10.

The reinforcing strips 70, 72, 74, 76 and the supplemental strips 94, 96may span the entire length of the channels 30, 32 (between bridgemembers 60, 62), or may span a length less than the entire length of thechannels 30, 32. Optionally, the reinforcing strips 70, 72, 74, 76 andthe supplemental strips 94, 96 may be combined with other strips to spanthe entire length of the channels, 30, 32. Further optionally, apredetermined number of strips may be placed at a predetermined spacingfrom one another to provide the blade with desired characteristics. In afurther optional configuration, only supplemental strips 94, 96 may beused such that all strips in the configuration are positionedsubstantially completely within the channel 30, 32. Even furtheroptionally, in this configuration, it is contemplated that all of thesupplemental strips may not bond to the at least one skin ply layer 100,102, 104, 106.

As also shown in FIG. 2, one or more skin ply layers 100, 102, 104, 106may be wrapped around the foam core 20. The one or more skin ply layers100, 102, 104, 106 may extend continuously along the first core face 22,top core edge 26, second core face 24 and bottom core edge 28. The oneor more skin ply layers 100, 102, 104, 106 may also be arranged inseparate sections, with each section oriented on one or more of thefirst core face 22, top core edge 26, second core face 24 and bottomcore edge 28. If more than one skin ply layer is used, the skin plylayers may be configured as concentric wrappings (as illustrated in FIG.2), or as one continuous spiral wrapping that forms multiple layers. Theat least one skin ply layer 100, 102, 104, 106 may contact the firststrip ends 78, 80, 82, 84 adjacent the first core face 22 and maycontact the second strip ends 86, 88, 90, 92 adjacent the second coreface 24. The skin ply layers 100, 102, 104, 106 may be made of prepregmaterial. The fibers in the prepreg material may be any suitable fibersincluding unidirectional and woven carbon fibers, optionally the sameprepreg material received in the channels 30, 32.

During molding (described below), the reinforcing strips 70, 72, 74, 76,and the supplemental strips 94, 96 are cured, creating a strong “I-beam”configuration as shown in FIG. 2 (see reinforcing strips 70, 72 andsupplemental strip 94 create an “I” and reinforcing strips 74, 76 andsupplemental strip 96 create an “I”). The I-beams may form a bridgebetween a first face 108 and a second face 110 of the at least one skinply layer 100, 102, 104, 106. The bridge may provide added strength tothe foam core 20 and increase the strength of the overall blade 10.

III. Method of Manufacture

Referring now to FIG. 5, a method for forming the reinforced hockeystick blade 10 is illustrated and generally designated 120. The methodgenerally includes providing a core element 20 at step 122. According toone embodiment, core element includes structural foam. For example, thecore element can include AIREX® C71 structural foam from 3A CompositesInternational AG, or Divinycell® HP130 structural foam from DIAB GroupAM. The energy-absorbing core material can include non-foam materials inother embodiments as desired. At step 124, one or more channels 30, 32are formed in the core element 20. The channels can be formed bypunching, cutting, or any other suitable foam forming method. One ormore foam core bridges 60, 62 may be preserved at the sides of the foamcore 20 to connect the portions of the foam core 20 defined by the oneor more channels 30, 32. For example, the one or more foam core bridges60, 62 may connect the upper core portion 50, the middle core portion 54and the lower core portion 52. In addition, the channels 30, 32 canextend generally parallel to each other, extending longitudinally fromthe toe region to the heel region. Other configurations are as possible,including configurations set forth below in connection with FIGS. 7-20.

At step 126, one or more reinforcing strips 70, 72, 74, 76 may beprovided and inserted transversely through the one or more channels 30,32. For example, the first strip ends 78, 80, 82, 84 may project fromthe foam core 20 adjacent the first core face 22, and the second stripends 86, 88, 90, 92 may project from the foam core 20 adjacent thesecond core face 24. The first strip ends 78, 80, 82, and 84 and thesecond strip ends 86, 88, 90, 92 may be folded over, as shown in FIG. 2,to place them closely adjacent the first core face 22 and the secondcore face 24. Additional strips may be inserted transversely through theone or more channels 30, 32 to overlap and layer on top of thereinforcing strips 70, 72, 74, 76. The same number of layered strips maybe positioned adjacent each portion of the first core face 22 and thesecond core face 24 to form a relatively flat area for the at least oneskin ply layer 100, 102, 104, 106 to bond to during molding. One or moreadditional supplemental strips 94, 96 may be inserted transverselythrough the channels 30, 32 so that the additional supplemental strips94, 96 are positioned substantially completely within the channel 30,32.

At step 128, the foam core 20 may be wrapped with at least one skin plylayer 100, 102, 104, 106 to form a preform hockey stick blade. The atleast one skin ply layer 100, 102, 104, 106 may be wrapped continuouslyalong the first core face 22, top core edge 26, second core face 24 andbottom core edge 28. If more than one skin ply layer is desired, thelayers may be concentric wrappings (as illustrated in FIG. 2), or may beone continuous skin ply layer that forms multiple layers via spiralwrapping. Further optionally, the one or more skin ply layers 100, 102,104, 106 may be formed from multiple separate sections that arepositioned on one or more of the first core face 22, top core edge 26,second core face 24 and bottom core edge 28. During wrapping, the one ormore skin ply layers 100, 102, 104, 106 may contact the first strip ends78, 80, 82, 84 adjacent the first core face 22 and may contact thesecond strip ends 86, 88, 90, 92 adjacent the second core face 24.

At step 130, the preform is cured under suitable temperature andpressure, and at step 132 the cured blade is removed from the mold. Thepreform can optionally be cured according to fixed displacement thermalmolding (FDTM) processes. During the curing process, the first stripends 78, 80, 82, 84 may become joined with the at least one skin plylayer 100, 102, 104, 106 adjacent the first core face 22 and the secondstrip ends 86, 88, 90, 92 may become joined with the at least one skinply layer 100, 102, 104, 106 adjacent the second core face 24. Duringmolding, the portions of the reinforcing strips 70, 72, 74, 76 and thesupplemental strips 94, 96 located within the channels 30, 32 may becompressed between the upper core portion 50, the middle core portion 54and the lower core portion 52. During cure, the strips 70, 72, 74, 76and supplemental strips 94, 96 may form a solid bridge between the firstface 108 and second face 110 of the at least one skin ply layer 100,102, 104, 106. The mold may then be cooled for de-molding.

The cured blade can optionally include a hollow hosel integrally formedwith the blade. For example, a hosel preform can be bladder molded whilethe blade preform is within the mold. That is, an air bladder positionedwithin a hosel preform can create pressure to force the hosel preformagainst the mold until the hosel and the blade cure. The hosel can beattached to a shaft at step 134 and finished at step 136. In otherembodiments, the preform can be integrated with a shaft layup and thensubjected to a curing process to obtain a one-piece product. Thefinishing process can include structural aspects such as deburring,sanding or grinding any imperfections out from the mold finish and caninclude aesthetic aspects such as painting, decaling or polishing.

In another embodiment, the above method 120 includes resin transfermolding rather than compression molding. In this embodiment, thereinforcing strips 70, 72, 74, 76, the supplemental strips 94, 96 andthe skin ply layers 100, 102, 104, 106 may be dry fabric materials andmay not be pre-impregnated with an epoxy resin. As one of skill in theart will appreciate, resin transfer molding involves injecting the resinseparately into a dry preform in a mold rather than including the resinas a preimpregnated material in the reinforcing strips and the skin plylayers.

Multiple tests have been conducted on blades constructed in accordancewith the method described above. As shown in FIG. 6, for example, hockeystick blades including a reinforced core element demonstrated anappreciable increase in blade strength. In particular, the maximumthree-point breaking force improved to over 700 lbs of force,demonstrating an increase of 200 lbs to 300 lbs over blades lacking areinforced core element. In addition, flexibility of the blade remainedwithin desirable parameters, being between 0.2228 inches of flexion and0.2701 inches of flexion.

IV. Additional Exemplary Embodiments

Referring now to FIGS. 7-8, a hockey stick blade according to anotherembodiment is illustrated and generally designated 210. The hockey stickblade 210 is structurally and functionally similar to the hockey stickblade 10 discussed above. In this embodiment, however, the foam core 220defines only a single channel 230. One or more reinforcing strips arereceived transversely through the channel 230 to reinforce the foam core220 substantially as set forth above in connection with FIGS. 1-4. Inaddition, the foam core 220 includes a first core face 222, a secondcore face 224, a top core edge 226, a bottom core edge 228, a toe coreedge 227 and a heel core edge 229. The channel 230 is defined in thefoam core 220 at a location between the top core edge 226 and the bottomcore edge 228, and between the toe core edge 227 and the heel core edge229. The channel 230 includes a first channel end 236 proximate the toeregion 14 and a second channel end 238 proximate the heel region 12.

As shown in FIG. 8, the upper core portion 250 and lower core portion252 may be attached to and continuous with one another via a first foamcore bridge member 260 and/or a second foam core bridge member 262. Thebridge members 260, 262 and the remainder of the foam core 220 may forma unitary, one-piece, monolithic structure, with the bridge members 260,262 closing the first end 236 and the second end 238 of the channel 230.

Another embodiment is shown in FIGS. 9-10 and is generally designated310. In this embodiment, the foam core 320 has two channels 330, 332that are oriented in an “X” configuration when viewed from the side. Asshown in FIG. 10, the foam core 320 may include an upper core portion350, a lower core portion 352 and two middle core portions 354 (one on afirst side of the crossing point of the “X” and a second on the otherside of the crossing point of the “X”). As with the above embodiments,the reinforcing strips 70, 72, 74, 76 may span the entire length ofchannels 330, 332. Optionally, the reinforcing strips 70, 72, 74, 76 mayspan a length less than the length of channels 330, 332. For example,the reinforcing strips 70, 72, 74, 76 may span each side of the channels330, 332 up to the crossing point of the “X” configuration. If thereinforcing strips 70, 72, 74, 76 span the entire length of the channels330, 332, a partial slit or other suitable configuration may be formedin the reinforcing strips 70, 72, 74, 76 at the crossing point of the“X” configuration to accommodate the crossing of the reinforcing strips70, 72, 74, 76. Optionally, there may be multiple channels andreinforcing strips criss-crossing one another at the same or differentangles if desired for a particular application.

Another embodiment of a hockey stick blade including a reinforced foamcore is shown in FIGS. 11-12 and generally designated 410. As shown inFIG. 11, the foam core 420 includes multiple small channels or slits 430extending from the first core face 22 to the second core face 24. Asshown in the sectional view of FIG. 12, one or more strings 450 havingmaterial preimpregnated with an epoxy resin may be routed through thechannels 430 in alternate directions in a zig-zag configuration. Thematerial may be any suitable material, including those listed above.Optionally, more strings 450 may be routed through the foam in the samezig-zag configuration as the first string 450. Further optionally, oneor more strings 450 may be added such that at least two strings 450 areoriented in a criss-cross configuration. In a criss-cross configuration,the at least two strings would form multiple figure “8” shapes betweenthe two bridge members 60, 62. In a further optional configuration, asmall gap may be maintained between the at least one string 450 and theat least one skin ply layer 100, 102, 104, 106 so that the at least oneskin ply layer 100, 102, 104, 106 may not directly bond with the strings450. Optionally, the small gap may be maintained so that the at leastone skin ply layer 100, 102, 104, 106 may not directly bond with theedges of the strings 450. In an even further optional configuration, theone or more strings 450 may be routed entirely through the foam core 420such that the one or more strings 450 never extend past the outersurfaces of the foam core 420. In this configuration, additionalchannels may be defined in the foam core 420 adjacent the first coreface 22 and the second core face 24 so that the one or more strings 450are routed within the foam core 420 to extend between adjacent channels430, instead of being routed around the foam core 420 as illustrated inFIG. 12. In each of these embodiments, the number of channels 430, thesize of the channels 430, the position of the channels 430, and thenumber of strings 450 may be altered to vary the characteristics of theblade.

In accordance with another embodiment, the hockey stick blade caninclude an adhesive film interposed between the reinforcing strips andthe outer plies. Referring now to FIGS. 13-14, a hockey stick bladeaccording to this embodiment is illustrated and generally designated500. The hockey stick blade is structurally and functionally similar tothe hockey stick blade of FIGS. 1-4, having a foam core 20 definingupper and lower channels 30, 32 for receipt of one or more reinforcingplies 70, 72, 74, 76 therein. The upper and lower channels 30, 32 extendlongitudinally from the heel region 12 of the hockey stick blade 10 tothe toe region 14 of the hockey stick blade 10, extending substantiallyparallel to the foam core upper edge 26 and lower edge 28.

As noted above, the hockey stick bade 10 additionally includes anadhesive film 502, 504, 506, 508 interposed between the reinforcingplies 70, 72, 74, 78 and the outer skin plies 100. As shown in FIG. 13,for example, an upper adhesive film 502 overlies the upper channel 30and a lower adhesive film 504 overlies the lower channel 32. Theadhesive film includes an inner surface 510 engaged with a reinforcingply, and an outer surface 512 engaged with an outer skin ply. As shownin FIG. 14, for example, an adhesive film 506 includes an inner surface510 opposite an outer surface 512. The inner surface 510 overlies andengages the reinforcing ply portions 70, 72 that fold over against thefoam core 20. The outer surface 512 underlies and engages the innermostouter skin ply 100. The remaining adhesive films 502, 504, 508 likewiseengage an underlying reinforcing strip and an outer skin ply 98.

As also shown in FIGS. 13-14, the upper adhesive films 502, 506 areoptionally coextensive in length L1 with the upper channel 30, and thelower adhesive films 504, 506 are optionally coextensive in length L1with the lower channel 32. While the lengths are shown as beingsubstantially equal in the present embodiment, the lengths can differ inother embodiments. In addition, each adhesive film optionally includes aheight H1 greater than or equal to the height of each channel 30, 32.For example, each adhesive film can include a height H1 betweenapproximately 0.1 inches and 1.0 inch, further optionally between about0.25 inches and 0.5 inches, extending over a channel having a height ofbetween about 1/32 inches and ⅛ inches, further approximately 1/16inches.

The adhesive film can be formed of any material to improve adhesionbetween the reinforcing strips 70, 72, 74, 86 and the skin plies 98. Forexample, the adhesive film 502 can include an epoxy film adhesive,optionally an epoxy film adhesive that is co-curable with the prepregused in the blade lay-up. In one embodiment, the adhesive film includesNB102 available from Newport Adhesives and Composites, Inc., of Irvine,Calif. Other films can be used in other embodiments as desired.Functionally, the adhesive film increases the bonding between thereinforcing strips 70, 72, 74, 76 and the skin plies 98. In addition,the adhesive film increases the flow of resin into the respectivechannel 30, 32. Mechanical testing of a hockey stick blade formedaccording to the present embodiment revealed an appreciable increase inblade strength. For example, three-point break testing of a hockey stickblade included an internal adhesive layer demonstrated an increase of100 lbs. in the maximum blade breaking force over hockey stick bladeslacking an adhesive film layer.

In accordance with another embodiment, the hockey stick blade caninclude outer skin plies having a reduced modulus to thereby reduce thestiffness of the completed blade. A hockey stick blade according to thisembodiment is structurally and functionally similar to the hockey stickblade of FIGS. 1-4, having a foam core 20 defining upper and lowerchannels 30, 32 for receipt of one or more reinforcing strips 70, 72,74, 76 therein. In this embodiment, however, the outer skin plies 100,102, 104, 106 are formed from a unidirectional tape having a lowermodulus. A lower modulus tape can include, for example, T700unidirectional graphite tape available from Toray Industries of Tokyo,Japan. Other tapes can be used in other embodiments as desired.

Lower modulus outer plies can generally have a higher toughness thanhigher modulus outer plies, while also being generally less expensivethan higher modulus outer plies. The substitution of a lower modulus plycan also offset an increase in blade stiffness attributed to theinternal reinforcing strips 70, 72, 74, 76. For example, a hockey stickblade formed according to the method of FIG. 5 can include an increasein weight of about 3-4 grams, while also adding 150 lbs. of maximumbreaking force and between about 0.010 and about 0.020 of stiffness tothe blade. When the method of FIG. 5 is modified to include a lowermodulus unidirectional tape, the resulting hockey stick blade canachieve the same beneficial blade flex with an increase in strength andtoughness and a decrease in material and production costs.

In accordance with another embodiment, the hockey stick blade caninclude a fewer number of outer plies to offset any increase instiffness attributed to the internal reinforcing strips. Referring nowto FIG. 15, a hockey stick blade according to this embodiment isillustrated and generally designated 550. The hockey stick blade 550 isstructurally and functionally similar to the hockey stick blade 10 ofFIGS. 1-4, having a foam core 20 defining upper and lower channels 30,32 for receipt of one or more reinforcing strips 70, 72, 74, 76 therein.However, in this embodiment the lay-up includes a fewer number of outerplies, optionally on one side of the lay-up, further optionally on theback side of the lay-up.

For example, the hockey stick blade 550 can include a lay-up beginningwith the foam core 20 and the reinforcing elements 70, 72, 74, 76substantially as described above in connection with FIGS. 1-4. Thelay-up can additionally include multiple outer skin plies 98encapsulating the foam core 20 and the reinforcing strips 70, 72, 74,76. The outer skin plies 98 can include, for example, woven orunidirectional graphite fiber prepreg, fiberglass fiber prepreg, aramidfiber prepreg, blend fiber prepreg, as well as any of the above pliesnot yet impregnated with a resin. In the present embodiment, the outerskin plies 98 including multiple plies of unidirectional graphiteprepreg 100, 102, 104 and an outer skin ply of woven graphite prepreg106. When modified in accordance with the present embodiment, at least aportion of at least one outer skin ply 98 is omitted in the lay-up ofthe hockey blade preform. As a result, the outer skin 98 can begenerally thicker (having a greater number of plies) at one portionthereof than at another portion thereof. In the present embodiment, therear facing portion of the hockey stick blade 550 can have a fewernumber of plies when compared to the forward facing portion of thehockey stick blade 500. In other embodiments, however, the forwardfacing portion of the hockey stick blade 550 can have a fewer number ofplies when compared to the rearward facing portion of the hockey stickblade 550. The resulting blade 550 can therefore be manufactured at alower material cost, while also achieving weight savings.

Further in accordance with this embodiment, the lay-up can be modifiedto include additional channels and reinforcing plies therein. Withreference to FIG. 16, the hockey stick blade 550 includes an addedchannel 31 approximately midway between the upper and lower channels 30,32. The added channel 31 includes reinforcing strips 552, 554, 556substantially as set forth above in connection with FIG. 2. In thisembodiment, the additional reinforced channel 31 can add between about 3grams and about 4 grams to the blade, while achieving an increase ofabout 150 lbs. in the maximum breaking force. The outer plies ofunidirectional tape 98, by comparison, add about 5 grams, contributingto an increase of about 50 lbs. in the maximum breaking force. Bymodifying the lay-up of FIG. 2 to include an additional channel 31 and areduced number of outer plies 98 in accordance with the presentembodiment, the resulting blade can achieve a desired blade strength,without excessive stiffness or weight. For example, the addition of areinforced channel 31 and the reduction of an outer ply can achieve anet increase of about 100 lbs. in the maximum breaking force and a netdecrease of between 1 and 2 grams in the weight of the finished blade.Also by example, the addition of a reinforced channel 31 and thereduction of two outer plies can achieve a net increase of about 50 lbs.in the maximum breaking force and a net decrease of about 6 to 7 gramsin the weight of the finished blade. Other combinations are alsopossible, including the further addition of a reinforced and/or thereduction in the outer plies and/or a change in the modulus of the outerplies.

As noted above, the reinforcing strips 70, 72, 74, 76, 94, 96, 552, 554,556 can be formed of a wide variety of materials to strengthen thehockey stick blade. Exemplary materials can include, for example, wovenor unidirectional graphite fiber prepreg, fiberglass fiber prepreg,blend fiber prepreg, as well as any of the above plies not yetimpregnated with an epoxy resin. As a further embodiment of the presentinvention, the reinforcing strips can include aramid to further limitcrack propagation from the lower blade edge 18 upwardly into the middlecore portion 54. For example, at least one of the reinforcing strips 70,72, 74, 76, 94, 96, 552, 554, 556 can include aramid fiber-reinforcedunidirectional tape, optionally being pre-impregnated with a suitableepoxy resin. Also by example, the at least one reinforcing stripincludes the lower-most reinforcing strip 76 subjacent the lower channel32. The at least one reinforcing strip 76 can act as a barrier to crackpropagation when a crack is formed in the lower blade edge 18. Inparticular, cracks that develop in the foam core 20 are generallyinitially confined to the lower core portion 52 by the reinforcing strip76. Other reinforcing strips can additionally include aramid fibersincluding, for example, all or a subset of the reinforcing stripsdepicted in FIGS. 2, 10, 12, 14-16.

In accordance with another embodiment, the hockey stick blade caninclude staggered or offset upper and lower reinforced channels.Alternatively, the channels can be of different lengths. Referring nowto FIGS. 17-18, a hockey stick blade according to this embodiment isillustrated and generally designated 600. The hockey stick blade 600 isstructurally and functionally similar to the hockey stick blade 10 ofFIGS. 1-4, having a foam core 20 defining upper and lower channels 602,604 for receipt of one or more reinforcing strips therein. The upper andlower channels 602, 604 originate in the toe region 14, extendingrearwardly toward the heel region 12. However, in this embodiment thelower channel 604 continues into the heel region 12, while the upperchannel 602 does not continue into the heel region 12, and insteadterminates forward of the heel region 12. In accordance with the presentembodiment, the lower channel 32 can reduce stress concentrations in theheel region, smoothing the transition from the blade 10 to the shaft614.

As depicted in FIG. 17, the upper reinforced channel 602 includes afirst end portion 606 and a second end portion 608. The lower reinforcedchannel 604 also includes a first end portion 610 and a second endportion 612. The first end portions 606, 610 are located in the toeportion 14 of the hockey stick blade 600. The lower second end portion612 is offset rearwardly of the upper second end portion 608, toward theheel region 12, improving the heel edge impact resistance of the hockeystick blade 600. In the cross-sectional view of FIG. 18, the lowerreinforced channel 604 is visible, while the upper reinforced channel602 terminates forwardly of line 18-18 and is therefore not visible inFIG. 18. In other embodiments, however, the upper reinforced channel 602extends further rearwardly than the lower reinforced channel 604,optionally into the heel region 12.

Optionally, the lower reinforced channel 604 defines a length greaterthan the length of the upper reinforced channel 602. Further optionally,the upper reinforced channel 602 defines a length greater than thelength of the lower reinforced channel 604. In still other embodiments,the upper and lower reinforced channels 602, 604 are substantially equalin length and originate and terminate offset from each other. That is,the upper and/or lower reinforced channels 602, 604 originatelongitudinally offset from each other, while also terminatinglongitudinally offset from each other. Other offset configurations canbe used in other embodiments as desired.

In accordance with a further embodiment, the hockey stick blade caninclude one or more tubular elements. Referring now to FIG. 19-20, ahockey stick blade according to this embodiment is illustrated andgenerally designated 650. The hockey stick blade 650 is structurally andfunctionally similar to the hockey stick blade 10 of FIGS. 1-4,including a foam core 20 defining upper and lower channels 30, 32, alsoreferred to herein as voids or cavities. However, in this embodimentupper and lower tubular elements 652, 654 are received within andgenerally positioned in the upper and lower channels 30, 32respectively, extending longitudinally from the toe region 14 toward theheel region 12 of the hockey stick blade 650.

Referring now to FIG. 19, each of the upper and lower tubular elements652, 654 are generally spaced apart from each other within the bladeinterior. The upper and lower tubular elements 652, 654 arelongitudinal, extending from a first (toe) end portion 656 to a second(heel) end portion 658. As shown in FIG. 20, the upper and lower tubularelements 652, 654 define a generally circular cross-section. In otherembodiments, however, the upper and lower tubular elements 652, 654 canbe beam-like, defining a generally rectangular or polygonalcross-section. Other suitable cross-sectional geometries, such as I-beamshaped, elliptical, triangular, or others, can be used as desired.

The upper and lower tubular elements 652, 654 can define across-sectional area that remains constant along their length or thatvaries along their length. For example, the upper and lower tubularelements 652, 654 can define an outer diameter that increases as thetubular elements 652, 654 extend rearwardly from the toe region 14toward the heel region 12. This increase can be continuous in someembodiments, optionally in proportion to the change in thickness of thehockey stick blade 650. In other embodiments this increase can bestepwise. Further by example, the upper and lower tubular elements 652,654 can define an outer diameter that remains substantially constant asthe tubular elements 652, 654 extend rearwardly from the toe region 14to the heel region 12. In these embodiments, the outer diameter of thetubular elements 652, 654 is generally less than the width of the foamcore 20, such that the tubular elements 652, 654 do not protrudelaterally outwardly of the foam core 20, being optionally entirelylaterally encapsulated within the foam core 20. In addition, the uppertubular element 652 can be slightly shorter than the lower tubularelement 654 in some embodiments, attributable to the concave bend in theupper edge 16 of the hockey stick blade 650. In other embodiments, theupper tubular element 652 can be slightly longer than the lower tubularelement 654, however.

The upper and lower tubular elements 652, 654 can be formed of anymaterial adapted to reinforce the upper and lower channels 30, 32,respectively. In one embodiment, the upper and lower tubular elementsare formed from a deformable thermoplastic material including, forexample, nylon, polyvinyl chloride (PVC), polyethylene (PE), andacrylonitrile butadiene styrene (ABS). In another embodiment, the upperand lower tubular elements are formed from a metal alloy including, forexample, 6061 aluminum alloy, a steel allow, a titanium allow or othermetal alloys. In addition, the tubular elements 702, 704 aresubstantially hollow in the present embodiment, having an air core todecrease the overall weight of the hockey stick blade 700. In otherembodiments the tubular elements 702, 704 can include a core material,including a foam core material or an expanding film core material forexample.

As depicted in FIG. 19, the upper and lower channels 30, 32 open to theexterior of the foam core 20 at the heel core edge 29. During assemblyof the blade lay-up, the tubular elements 652, 654 are inserted into theupper and lower channels 30, 32 formed in the foam core 20. Duringmolding, the tubular elements 652, 654 can change shape and/or thicknessto accommodate the final shape of the hockey stick blade 650. Forexample, the tubular elements can be of a circular cross-section whenplaced in the mold. During molding, the front to back dimension of thetubular elements 652, 654 can be reduced under the pressure and forcesof the mold. In turn, the tube is deformed, optionally from a circularcross-section to an elliptical cross section.

The tubular elements 652, 654 provide strength, stiffness and toughnessto the foam core 20, reinforcing the cured blade 650 substantially asset forth above in connection with FIGS. 1-18. The hockey stick blade650 can optionally include an adherent interposed between the tubularelements 652, 654 and the foam core 20. The adherent can include, forexample, a film adhesive, optionally an epoxy film adhesive that isco-curable with the prepreg used in the blade lay-up. In one embodiment,the adherent includes NB102 available from Newport Adhesives andComposites, Inc., of Irvine, Calif. Other adhesives can be used in otherembodiments as desired.

To reiterate, the tubular elements 652, 654 can be hollow and can extendlongitudinally from the toe portion 14 to the heel portion 12 of theblade 650. However, the tubular elements 652, 654 can also extendvertically between the tope edge of the blade 16 to the bottom edge ofthe blade 18, or in various other orientations. The tubular elements652, 654 can be constructed from a ductile and deformable material, andof a thickness that permits the tubular elements 652, 654 to deform whenmolded. Generally, the tubular elements 652, 654 are capable of beingdeformed from a first cross-sectional shape to a second cross-sectionalshape under mold pressure. That is, during compression within the moldcavity, at least a portion of the tubular elements 652, 654 can deform.For example, the tubular elements 652, 654 can bend, buckle, or crushslightly to take on a second cross-sectional shape (shown in phantom inFIG. 20) different from a first cross-sectional shape (shown in solid inFIG. 20). While in the mold, heat can be applied to cure the bladepreform. The mold cavity can be heated to greater than 250° F. in someembodiments, optionally between about 250° F. and about 500° F. Duringthis curing process, the tubular elements 652, 654 can soften, becomingmore readily deformable within the foam core 20.

After the blade preform is cured, the cured blade is removed from themold cavity, and the tubular elements 652, 654 remain in their deformedstate. The tubular elements 652, 654 can provide additional strength,rigidity, stiffness and/or toughness to the cured blade 650. Further, ifthe exterior skin layer begins to crack under extreme loads, the bladecan maintain its integrity without brittle failure, at least partiallydue to the tubular elements 652, 654. It should be noted that in someconstructions the blade will taper in width from the toe to the heel.Thus, in some cases, only a portion of the tubular elements 652, 654will deform. For example, toward the toe of the blade where the blade isusually “thin,” the tubular elements 652, 654 can deform more into aflattened elliptical form. In contrast, toward the heel of the blade,where the width is usually “thick,” the tubular elements 652, 654 canmaintain a generally circular or original geometric shape.

The above description is that of current embodiments of the invention.Various alterations and changes can be made without departing from thespirit and broader aspects of the invention as defined in the appendedclaims, which are to be interpreted in accordance with the principles ofpatent law including the doctrine of equivalents. This disclosure ispresented for illustrative purposes and should not be interpreted as anexhaustive description of all embodiments of the invention or to limitthe scope of the claims to the specific elements illustrated ordescribed in connection with these embodiments. For example, and withoutlimitation, any individual element(s) of the described invention may bereplaced by alternative elements that provide substantially similarfunctionality or otherwise provide adequate operation. This includes,for example, presently known alternative elements, such as those thatmight be currently known to one skilled in the art, and alternativeelements that may be developed in the future, such as those that oneskilled in the art might, upon development, recognize as an alternative.Directional terms, such as “vertical,” “horizontal,” “top,” “bottom,”“upper,” “lower,” “inner,” “inwardly,” “outer” and “outwardly,” are usedto assist in describing the invention based on the orientation of theembodiments shown in the illustrations. The use of directional termsshould not be interpreted to limit the invention to packages of anyspecific orientation(s). Further, the disclosed embodiments include aplurality of features that are described in concert and that mightcooperatively provide a collection of benefits. The present invention isnot limited to only those embodiments that include all of these featuresor that provide all of the stated benefits, except to the extentotherwise expressly set forth in the issued claims. Any reference toclaim elements in the singular, for example, using the articles “a,”“an,” “the” or “said,” is not to be construed as limiting the element tothe singular. Any reference to claim elements as “at least one of X, Yand Z” is meant to include any one of X, Y or Z individually, and anycombination of X, Y and Z, for example, X, Y, Z; X, Y; X, Z; and Y, Z.

The Invention claimed is:
 1. A composite hockey stick blade including aheel portion and a toe portion, the composite hockey stick bladecomprising: a core element including a first core face opposite a secondcore face, the core element defining a through-hole therebetween, thethrough-hole extending longitudinally along a portion of the coreelement to define a channel having a first channel end portion and asecond channel end portion, the core element including an upper coreportion above the channel and a lower core portion below the channel,the core element including a core bridge member extending from the uppercore portion to the lower core portion so that the upper core portion,core bridge member and lower core portion are joined and contiguous withone another, forming a unitary, monolithic structure, with the corebridge member bounding the first channel end portion; a firstfiber-reinforced strip disposed in the channel to increase the strengthof the core element, the first fiber-reinforced strip extendinglongitudinally from the first channel end portion to the second channelend portion, the first fiber reinforced strip including a first stripend, a second strip end distal from the first strip end, and anintermediate portion therebetween, the intermediate portion extendingtransversely across the channel, the first strip end projecting out fromthe channel and positioned adjacent the first core face, the secondstrip end projecting out from the channel end positioned adjacent thethe second core face; and a plurality of outer plies substantiallyencapsulating the core element and the first fiber-reinforced strip, atleast one of the plurality of outer plies engaging at least one of thefirst strip and the second strip end, wherein the channel and the firstfiber-reinforced strip extend along a substantial portion of the bladelength between the heel portion and the toe portion.
 2. The compositehockey stick blade of claim 1 wherein the first strip end, intermediateportion and second strip end cooperatively form a C-shape.
 3. Thecomposite hockey stick blade of claim 2 comprising a second fiberreinforced strip disposed transversely through the channel, adjacent theintermediate portion.
 4. The composite hockey stick blade of claim 3wherein the second fiber reinforced strip includes a third strip end anda fourth strip end, the third strip end engaging the first core face,the fourth strip end engaging the second core face.
 5. The compositehockey stick blade of claim 3 wherein the second fiber reinforced stripcontacts the first core face the second core face.
 6. The compositehockey stick blade of claim 5 wherein the second fiber reinforced stripis generally of a C-shape.
 7. The composite hockey stick blade of claim5 comprising a third fiber reinforced strip extending transverselythrough the channel, between the first fiber reinforced strip and thesecond fiber reinforced strip.
 8. The composite hockey stick blade ofclaim 1 wherein the first reinforcing strip includes a plurality offiber-reinforced plies.
 9. The composite hockey stick blade of claim 8wherein the plurality of fiber-reinforced plies include at least one ofgraphite, carbon, aramid, and fiberglass.
 10. The composite hockey stickblade of claim 1 wherein the channel is a first channel, the coreelement further defining a second channel therein, below the lower coreportion the second channel being substantially parallel to andvertically spaced apart from the first channel.
 11. The composite hockeystick blade of claim 1 wherein the core element is a unitary structuralfoam core.
 12. A composite hockey stick blade including a heel portionand a toe portion, the composite hockey stick blade comprising: a coreelement including a first core face opposite a second core face anddefining a through-hole therebetween, the through-hole extendinglongitudinally along a portion of the core element to define a channelhaving first and second end portions; a fiber-reinforced materialreceived within the channel to increase the strength of the coreelement, the fiber-reinforced material extending longitudinally from thefirst end portion to the second end portion, and extending transverselyacross the channel, the fiber-reinforced material engaging the firstcore face and the second core face; and a plurality of outer pliessubstantially encapsulating the core element and the fiber-reinforcedmaterial, wherein the longitudinal channel and the fiber-reinforcedmaterial extend along a substantial portion of the blade length betweenthe heel portion and the toe portion, wherein the channel is bounded byan upper core portion and a lower core portion, with a first core bridgemember and a second core bridge member joining the upper and lower coreportions at the channel first and second end portions to form a unitary,one piece structural foam core, wherein the fiber-reinforced materialincludes a first strip end distal from a second strip end with anintermediate portion therebetween, wherein the first strip end isadjacent the first core face, and terminates adjacent the channel,wherein the second strip end is adjacent the second face and terminatesadjacent the channel.
 13. The composite hockey stick blade of claim 1wherein the first strip end, intermediate portion and second strip endcooperatively form a C-shape.
 14. The composite hockey stick blade ofclaim 13 wherein the second core bridge member is distal from the firstcore portion, wherein the first core bridge member is in the heel of theblade, wherein the second core bridge member is in the toe of the blade.